Volkswagen Workshop Service and Repair Manuals

Removing and installing alternator, 1.9 l TDI engine with diesel particulate filter   Caution When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed → Chapter. Removing: Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Locking pin -T10060 A- –  Disconnect battery → Chapter.

–  First pull engine cover upwards -arrows A- and then forwards -arrow B-.   Note

t  All hose connections of charge air system are secured with spring-type clips or push-on connectors. The following points must be observed for push-on connectors: t  Release push-on connection by pulling securing ring -arrow-. t  Pull off hose/pipe without tools.

–  Separate hose connection -arrows-. –  Remove charge air pipe -1- upwards.

–  Disconnect DF wire connector -1- and pull off protective cap -2-.

–  Unscrew B+ (battery positive) wire -arrow- from alternator. –  Pull fuel filter out of bracket and place to one side. When doing this, the fuel hoses can remain connected.   Caution Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be destroyed! –  Mark direction of rotation of poly V-belt.

–  Release tension of poly V-belt by swivelling tensioning element in direction of -arrow- using a 16 mm open-jaw spanner.

–  Lock tensioning element using locking pin -T10060 A-. –  Remove poly V-belt.

–  Remove securing bolts of alternator -arrows-.

–  Unbolt cable retainer from alternator -arrow-. –  Remove alternator. Installing: Install in the reverse order of removal. When doing this, note the following:   Caution t  In order to avoid damage to cylinder block and ancillaries bracket, adhere strictly to the tightening sequence for the ancillaries bracket → Chapter. t  When installing used poly V-belts observe the direction of rotation marked on removal! t  Before installing poly V-belt, ensure that all ancillaries (alternator, air conditioning compressor) are secure. t  When fitting belt, ensure that poly V-belt seats correctly in pulleys!

–  Drive threaded sleeves -A- about 4 mm in direction of -arrow- out of alternator housing.

–  Tighten cable retainer -arrow- to rear of alternator in 9 o'clock position.   Note

t  All hose connections of charge air system are secured with spring-type clips or push-on connectors. The following points must be observed for push-on connectors: t  Push on hose or pipe without tools. t  Ensure that locking lugs are securely engaged -arrow- –  Tighten threaded connections to torques specified in assembly overview → Chapter.   Caution Observe notes for battery terminal clamp bolt → Chapter. –  Reconnect battery → Chapter. –  Start engine and check belt is running correctly. –  Switch off engine.